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Step/Maintenance work on Workstation (SingleProc)

Legend
Legend

Hi all,

 

I have a model based on a real production line, a few workcells with a few workstations inside each cell.

Robots move parts inside each workcell and AGV's move parts from each workcell to the next one.

 

In the real word there is a request to have some maintenance/setup work. This happening every x hours and last for xx minutes.

The operator is stepping to the workstation, after the last part completion he start the required work.

It includes tool changes, greasing, recalibration, run a first shot to make sure the workstation run correclty again and can continue the normal production. To simplify I wrap up all this work into single service.

 

I started with a failure which I can define first start time, any further start time and duration. I have a failure importer to get the worker move the the workstation.

This works fine....

 

I experience the situation the workcell get stuck when the operator does the setup/maintenance work.

I don't know if the last part has been completed. It stays in the machine.

 

What is the correct way to implement this service in the plant simulation ?

 

I have a chart which shows the operator occupation.

For the real world, people like to know how many service worker are required to run the production line.

 

 

Kind regards

Marco

12 REPLIES 12

Re: Step/Maintenance work on Workstation (SingleProc)

Phenom
Phenom

When simulating production lines you are ( apart form others)

 

interested in the  simulated performance ( jobs per hour / per shift / per day).

 

The impact of the maintenance (time) is usually considered in the net production time ,

 

where the maintenance(time)  has already been excluded from.

 

You therefore do not simulate the maintenance impact as the impact

 

 is already considered through the (reduced) net production time.

 

The maintenance operator count can be individually calculated through necessary tasks

 

and is not determined through the simulation.

 

To in increase the production time, maintenance tasks often are "squeezed" into the pauses / end of shift.

 

or automated like tip dressing- /changing.

 

Emptying the production line is usually done before a production batch change

 

Therefore:

 

What is your simulation target ?

 

Do you have to consider the maintenance in this level of detail ?

 

 

 

 

 

 

 

Re: Step/Maintenance work on Workstation (SingleProc)

Legend
Legend

Hi,

 

the simulation target is to help setting up and optimizing the production in the real world.

I have a table with the real process times, they will also provide me the part transiting times inside each wortcell and from workcell to workcell.

Management want to know from the simulation:

- what is the occupation level of this operator (worker) who is:

 bringing raw material to the production line, carries away part sets after completion, does the setup/maintenance work.

I have added a chart which shows a pie of the worker occupation (this is very efficient view).

- how the production efficiency be improved (adding, changing locations, re-using machinees/ workstations etc...)

 

Re: Step/Maintenance work on Workstation (SingleProc)

Phenom
Phenom

Please add the chart

 

Re: Step/Maintenance work on Workstation (SingleProc)

Legend
Legend

Sorry, but I don't know what you mean...?

 

I have a chart in my model to show the worker utilization as a pie chart.

 

Re: Step/Maintenance work on Workstation (SingleProc)

Phenom
Phenom

this was a misunderstanding.

 

It sounded like if you added a chart to your post to highlight

 

the  model performance improvements.

 

In any case for estimating the operator utilization

 

the usage of yamazumi charts is helpful.

 

The data required for the charts is probably the same data

 

you use as input for operator simulation e.g. walking paths of  operators

 

and operator processing times.

 

 

 

 

Re: Step/Maintenance work on Workstation (SingleProc)

Legend
Legend

Hi again,

 

took some time ... had to work on other projects.

 

As you recommend to use a Yamazumi chart, I am unable to find this type of chart in tecnomatix.

There is no property to switch the 'Chart' to a speciific type.

I am using V13.1, probably you have a higher version.

 

Regards

 

Re: Step/Maintenance work on Workstation (SingleProc)

Phenom
Phenom

Yamazumi charts are not part of Plant Simulation

 

But are used manually determine the Worker utilization (agmonst other data)

 

What I am on about, is although oyf course you can simulate the operator behaviour

 

it sometimes maybe simpler/ quicker to manually calculate it with the same / similiar  input data.

Re: Step/Maintenance work on Workstation (SingleProc)

Legend
Legend

OK, yes

I can use the existing data an calculate what I need, I will work on this later.

 

To return to my original question:

What is the correct way to implement service/maintenance in the plant simulation ?

 

I started with a failure, where I can define first start time, any further start time and duration. I have a failure importer to get the worker move the the workstation....

 

Regards

Re: Step/Maintenance work on Workstation (SingleProc)

Phenom
Phenom

The intended way to define setups including worker is

 

  • Setting a Set-up time (s. station Times tab)

 

  • Setting a Set-up event ( s. station Set-Up tab)

 

  • Setting the Set-up  importer ( s. station Importer tab)

 

Setting the failure as a Set-up interruption should also work but the Set-up statistics will

 

logged under failure statistics.